Inspection system for turbine rotors

ABSTRACT

An inspection system includes a first ultrasonic probe positioned on and configured to move along a surface of a component. The first ultrasonic probe transmits ultrasonic energy. The inspection system also includes a second ultrasonic probe positioned on and configured to move along the surface of the component opposite the first probe. The second ultrasonic probe receives the ultrasonic energy transmitted by the first ultrasonic probe. Additionally, the inspection system includes a probe alignment system in communication with the first ultrasonic probe and the second ultrasonic probe. The probe alignment system is configured to analyze an energy characteristic for the ultrasonic energy received by the second ultrasonic probe to determine if a displacement characteristic for at least one of the first ultrasonic probe and the second ultrasonic probe requires adjustment.

TECHNICAL FIELD

The disclosure relates generally to an inspection system, and moreparticularly, to inspection probes of an inspection system and a processof maintaining a desired alignment between the inspection probes of theinspection system.

BACKGROUND

Over the operational life of a turbine system, components of the systemrequire regular inspection and/or maintenance. The inspection processesperformed on the turbine system may ensure that the components are notdamaged, obstructed, properly aligned/positioned, and/or functioning ata desired efficiency level so the turbine system may generate thegreatest amount of energy without damaging the system. When theinspection process determines that there is an operational and/orfunctional issue with a component of the turbine system (e.g., damaged,misaligned and so on), maintenance (e.g., repair, replacement and thelike) may be performed on the component and/or system before the turbinesystem become operational again.

Adequate inspection of the components of the turbine system may bedifficult however because of the configuration of the system. Forexample, a rotor of the turbine system may be encased and/or enclosedwithin a housing and may include and/or be surrounded by a plurality offeatures (e.g., turbine buckets, stators and so on) crucial to theoperation of the turbine system. As a result, the clearance andaccessibility of the rotor of the turbine system may be limited; makinginspection of the rotor difficult. In conventional processes, the rotormay be visually inspected by an operator by removing some components onand/or surrounding the rotor. However, the quality of the visualinspection may vary and may depend on the operator conducting theinspection.

In other conventional processes, the rotor may be removed from thehousing, and conventional inspection devices, such as sensors, may beused when performing the inspection process. However, the conventionalinspection devices may have a difficult time accurately inspecting therotor because of the number of unique geometries and/or featuresincluded on the rotor. Specifically, the non-uniform geometries and/orfeatures included on the rotor of the turbine system may obstruct and/orblock lines of sight between the conventional inspection devices used toinspect the rotor. Where the line of sight is obstructed, the results ofthe inspection generated by the conventional inspection device may beskewed and/or incomplete because the conventional inspection deviceshave trouble accurately inspecting areas of the rotor that include theseunique geometries and/or features.

SUMMARY

A first aspect of the disclosure provides an inspection system. Theinspection system may include a first ultrasonic probe positioned on andconfigured to move along a surface of a component. The first ultrasonicprobe may be configured to transmit ultrasonic energy. The inspectionsystem may also include a second ultrasonic probe positioned on andconfigured to move along the surface of the component opposite the firstprobe. The second ultrasonic probe may be configured to receive theultrasonic energy transmitted by the first ultrasonic probe.Additionally, the inspection system may include a probe alignment systemin communication with the first ultrasonic probe and the secondultrasonic probe. The probe alignment system may be configured toanalyze an energy characteristic for the ultrasonic energy received bythe second ultrasonic probe to determine if a displacementcharacteristic for at least one of the first ultrasonic probe and thesecond ultrasonic probe requires adjustment.

A second aspect of the disclosure provides a rotor. The rotor mayinclude a plurality of features formed on and extending from an exposedsurface, and an inspection system. The inspection system may include atleast one transmitter probe positioned on the exposed surface andadjacent the plurality of features. The at least one transmitter probemay be configured to transmit energy. The inspection system may alsoinclude at least one receiver probe positioned on the exposed surfaceand separated from the at least one transmitter probe by the pluralityof features. The at least one receiver probe may be configured toreceive the energy transmitted by the at least one transmitter probe.Additionally, the inspection system may include a probe alignment systemin communication with the at least one transmitter probe and the atleast one receiver probe. The probe alignment system may be configuredto analyze an energy characteristic for the ultrasonic energy receivedby the at least one receiver probe to determine if a displacementcharacteristic for at least one of the at least one transmitter probeand the at least one receiver probe requires adjustment.

A third aspect of the disclosure provides a method for aligninginspection probes. The method may include moving a first ultrasonicprobe along a surface of a component. The first ultrasonic probe may beconfigured to transmit energy. The method may also include moving asecond ultrasonic probe along the surface of the component, where thesecond ultrasonic probe may be configured to receive the energytransmitted by the first ultrasonic probe. Additionally, the method mayalso include analyzing an energy characteristic for the energy receivedby the second ultrasonic probe, and adjusting a displacementcharacteristic for at least one of the first ultrasonic probe and thesecond ultrasonic probe based on the analyzed energy characteristic.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be readily understood by the following detaileddescription in conjunction with the accompanying drawings, wherein likereference numerals designate like structural elements, and in which:

FIG. 1 shows a schematic view of a steam turbine system according toembodiments.

FIG. 2 depicts a side view of a portion of a rotor of the steam turbinesystem of FIG. 1, and an inspection system, according to embodiments.

FIG. 3 depicts a side view of a distinct portion of a rotor of the steamturbine system of FIG. 1, and an inspection system, according toembodiments.

FIG. 4 depicts a side view of a portion of a rotor of the steam turbinesystem of FIG. 1, and an inspection system, according to additionalembodiments.

FIG. 5 depicts a flow chart of a process for aligning inspection probesof an inspection system, according to embodiments.

It is noted that the drawings of the disclosure are not necessarily toscale. The drawings are intended to depict only typical aspects of thedisclosure, and therefore should not be considered as limiting the scopeof the disclosure. In the drawings, like numbering represents likeelements between the drawings.

DETAILED DESCRIPTION

Reference will now be made in detail to representative embodimentsillustrated in the accompanying drawings. It should be understood thatthe following descriptions are not intended to limit the embodiments toone preferred embodiment. To the contrary, it is intended to coveralternatives, modifications, and equivalents as can be included withinthe spirit and scope of the described embodiments as defined by theappended claims.

The following disclosure relates generally to an inspection system, andmore particularly, to inspection probes of an inspection system and aprocess of maintaining a desired alignment between the inspection probesof the inspection system.

These and other embodiments are discussed below with reference to FIGS.1-4. However, those skilled in the art will readily appreciate that thedetailed description given herein with respect to these Figures is forexplanatory purposes only and should not be construed as limiting.

Turning to FIG. 1, a schematic depiction of a steam turbine system 100is shown according to embodiments of the disclosure. Steam turbinesystem 10, as shown in FIG. 1 may be a conventional steam turbinesystem. As such, a brief description of the steam turbine system 100 isprovided for clarity. As shown in FIG. 1, steam turbine system 100 mayinclude a steam turbine component 102, including a high-pressure section104, an intermediate-pressure section 106 and a low-pressure section108, coupled to a rotor 110 of steam turbine system 10. Rotor 110 mayalso be coupled to a generator 112 for creating electricity duringoperation of steam turbine system 10. As shown in FIG. 1, steam turbinesystem 100 may also include a condenser 118 in fluid communication withlow-pressure section 108 of steam turbine component 102, a pump 120 influid communication with condenser 118 and a heat recovery steamgeneration (HRSG) 122 in fluid communication with the pump and steamturbine component 102. The components (e.g., condenser 118, pump 120,HRSG 122) of steam turbine system 100 may be in fluid communication withone another via steam conduits 124.

During operation of steam turbine system 10, as shown in FIG. 1, steamis generated by HRSG 122 and provided to steam turbine component 102.More specifically, HRSG 122, amongst other steam sources (not shown),may provide steam to high-pressure section 104, intermediate-pressuresection 106 and low-pressure section 108 via conduits 124 to flowthrough steam turbine component 102. Each section (e.g., low-pressuresection 108) of steam turbine component 102 may include a plurality ofturbine airfoils including a plurality of stages of buckets positionedin series on rotor 110, and a plurality of stator nozzles positionedadjacent the plurality of buckets. As steam flows over each stage ofbuckets, rotor 110 may be rotated and generator 112 may create power(e.g., electric current). The plurality of corresponding stator nozzlesmay aid in directing the steam toward the plurality of stages of bucketsduring operation of steam turbine system 10. The steam may exit steamturbine component 102, specifically low-pressure section 108, and may becondensed by condenser 118 and provided to HRSG 122 via pump 120. Thecondensed-steam may then aid in the generation of more steam by HRSG 122and may adjacently be provided to steam turbine component 102.

As used herein, the terms “axial” and/or “axially” refer to the relativeposition/direction of objects along axis (A), which is substantiallyparallel with the axis of rotation of steam turbine system 100 (inparticular, the rotor section). As further used herein, the terms“radial” and/or “radially” refer to the relative position/direction ofobjects along axis (R), which is substantially perpendicular with axis(A) and intersects axis (A) at only one location. Additionally, theterms “circumferential” and/or “circumferentially” refer to the relativeposition/direction (C) of objects along a circumference which surroundsaxis (A) but does not intersect the axis (A) at any location.

FIG. 2 depicts a side view of a portion of rotor 110 of steam turbinesystem 100, according to embodiments. The portion of rotor 110 depictedin FIG. 2 may be a portion of rotor 110 positioned within a section(e.g., low-pressure section 108) of steam turbine component 102. In anon-limiting example, rotor 110 may be completely removed from anenclosure of the section of steam turbine component 102 that may houseand/or surround the portion of rotor 110 when performing the inspectionprocess discussed herein. Where rotor 110 is completely removed from theenclosure, rotor 110 may undergo a surface cleaning and/or rougheningprocess (e.g., sandblasting) prior to performing the inspection process.In other non-limiting examples, rotor 110 may remain in a portion (e.g.,half-shell) of the enclosure during the inspection process, oralternatively, rotor 110 may remain in the entire enclosure of thesection of steam turbine component 102 where portions of rotor 110 maybe accessible to the components configured to perform the inspectionprocess.

Rotor 110 may include an exposed surface 126 and a plurality of features128 formed on exposed surface 126. More specifically, the plurality offeatures 128 of rotor 110 may be formed on, extend from and/or projectradially from exposed surface 126 of rotor 110. The plurality offeatures 128 of rotor 110 may also be positioned and/or formed onexposed surface 126 substantially around the circumference of rotor 110.In a non-limiting example shown in FIG. 2, the plurality of features 128may include dovetails formed on and circumferentially around rotor 110.The dovetails may couple the turbine buckets (not shown) of steamturbine system 100 to rotor 110. Although only a single row of theplurality of features 128 are shown, it is understood that rotor 110 ofsteam turbine system 100 may include multiple rows of the plurality offeatures 128 formed on and separated axially along the length of rotor110. Additionally, it is understood that the plurality of features 128of rotor 110 may include various parts, segments, transitions and/orother element that may be formed on and extend from exposed surface 126of rotor 110.

FIG. 2 also depicts an inspection system 130, according to embodiments.Portions of inspection system 130 may be positioned on or adjacent rotor110 in order to perform an inspection of rotor 110 and/or the pluralityof features 128 formed on rotor 110. Inspection system 130 may includeat least one transmitter probe 132 (hereafter, “transmitter probe 132”)positioned on or substantially adjacent to exposed surface 126 of rotor110. When positioned on exposed surface 126, transmitter probe 132 maybe releasably coupled to rotor 110 during the inspection processdiscussed herein. Alternatively, when transmitter probe 132 ispositioned adjacent exposed surface 126, transmitter probe 132 may besuspended in the space directly adjacent to rotor 110 using any suitabledevice or system capable of holding and/or positioning transmitter probe132 adjacent rotor 110. Additionally, as shown in FIG. 2, transmitterprobe 132 may be positioned adjacent a first side 134 of the pluralityof features 128 (e.g., dovetail) formed on and extending from exposedsurface 126 of rotor 110. Transmitter probe 132 may be configured totransmit energy toward and/or through rotor 110. As discussed in detailbelow, the energy transmitted by transmitter probe 132 may be utilizedto inspect rotor 110 and/or the plurality of features 128 formed onrotor 110, and may be used to maintain a desired spacing and/oralignment between transmitter probe 132 and a receiver probe ofinspection system 130 during the inspection process. In a non-limitingexample, transmitter probe 132 may be an ultrasonic, phased arraytransducer that may transmit ultrasonic energy. Although one transmitterprobe 132 is depicted in FIG. 2, it is understood that a plurality oftransmitter probes may be positioned on rotor 110 and utilized in theinspection process discussed herein.

Transmitter probe 132 may be configured to move around rotor 110.Specifically, transmitter probe 132 may be configured to movecircumferentially around exposed surface 126 of rotor 110 during theinspection process. In a non-limiting example where transmitter probe132 is positioned on and/or releasably coupled to rotor 110, transmitterprobe 132 may move circumferentially around rotor 110 along exposedsurface 126. In another non-limiting example where transmitter probe 132is positioned adjacent exposed surface 126 of rotor 110, the suitabledevice or system holding and/or positioning transmitter probe 132adjacent rotor 110 may move transmitter probe 132 circumferentiallyaround rotor 110 along exposed surface 126.

As shown in FIG. 2, inspection system 130 may include a first propulsionassembly 136 that may automate the movement of transmitter probe 132around rotor 110 and/or along exposed surface 126. First propulsionassembly 136 may be coupled or fixed to transmitter probe 132, and maycontact exposed surface 126 of rotor 110. As a result of contactingexposed surface 126, first propulsion assembly 136 may also releasablecouple and/or position transmitter probe 132 on exposed surface 126 ofrotor 110 as well. First propulsion assembly 136 may include anysuitable elements, device and/or components that may be configured tomove transmitter probe 132 along exposed surface 126 of rotor 110. In anon-limiting example, first propulsion assembly 136 may include aplurality of magnetic wheels that may contact, move along andmagnetically couple transmitter probe 132 to exposed surface 126 ofrotor 110. In the non-limiting example, first propulsion assembly 136may also include a drivetrain system coupled to and configured to drivethe magnetic wheels of first propulsion assembly 136 to move transmitterprobe 132 along exposed surface 126 and around rotor 110. Furthermore,first propulsion assembly 136 may include a magnetic track coupled toexposed surface 126 of rotor 110, which may receive the magnetic wheelsand maintain transmitter probe 132 on a desired path (e.g., maintaindistance (D) between transmitter probe 132 and a receiver probe) whenmoving around rotor 110. As discussed herein, first propulsion assembly136 may be in communication with a probe alignment system which mayengage first propulsion assembly 136 to move transmitter probe 132around rotor 110, and adjust displacement characteristics of transmitterprobe 132 using first propulsion assembly 136 to maintain an alignmentbetween transmitter probe 132 and at least one receiver probe ofinspection system 130.

In another non-limiting example, transmitter probe 132 may be manuallymoved along exposed surface 126 of rotor 110. Similar to firstpropulsion assembly 136 shown in FIG. 2, inspection system 130 mayinclude suitable devices, components and/or assemblies for allowingtransmitter probe 132 to be manually moved around rotor 110 and/or alongexposed surface 126. Similar to the example discussed above, a pluralityof magnetic wheels may be coupled to transmitter probe 132 and maycontact, move along and magnetically couple transmitter probe 132 toexposed surface 126 of rotor 110. An operator performing the inspectionprocess on rotor 110 may manually move transmitter probe 132 alongexposed surface 126 and around rotor 110 as discussed herein. In thenon-limiting example where transmitter probe 132 is moved manually, themagnetic wheels on transmitter probe 132 may maintain the releasablecoupling between transmitter probe 132 and rotor 110, while allowing theoperator to move transmitter probe 132 along exposed surface 126 withminimal friction. In the non-limiting example where transmitter probe132 is moved manually and as discussed in detail below, first propulsionassembly 136 may be in communication with a probe alignment system whichmay analyze energy characteristics of inspection system 130 and provideindicators to an operator when displacement characteristics oftransmitter probe 132 may require adjustment. Adjusting the displacementcharacteristics of transmitter probe 132 may maintain an alignmentbetween transmitter probe 132 and at least one receiver probe ofinspection system 130 during the inspection process.

As shown in FIG. 2, inspection system 130 may also include at least onereceiver probe 138 (hereafter, “receiver probe 138”). Receiver probe 138may be positioned on or substantially adjacent to exposed surface 126 ofrotor 110. Similar to transmitter probe 132, when receiver probe 138 ispositioned on exposed surface 126, receiver probe 138 may be releasablycoupled to rotor 110. Alternatively, when receiver probe 138 ispositioned adjacent exposed surface 126, receiver probe 138 may besuspended in the space direct adjacent to rotor 110 using a similardevice or system as transmitter probe 132, as discussed herein. As shownin FIG. 2, receiver probe 138 may be positioned adjacent a second side140 of the plurality of features 128 (e.g., dovetail) formed on andextending from exposed surface 126 of rotor 110. Specifically, receiverprobe 138 may be positioned adjacent a second side 140, opposite thefirst side 134 of the plurality of features 128 of rotor 110 and/oropposite transmitter probe 132. As shown in FIG. 2, the plurality offeatures 128 of rotor 110 may substantially separate transmitter probe132 and receiver probe 138, and may also substantially obstruct, obscureand/or block a line of sight between transmitter probe 132 and receiverprobe 138. As a result of separating transmitter probe 132 and receiverprobe 138, the plurality of features 128 of rotor 110 may substantiallyprevent transmitter probe 132 from transmitting energy directly toreceiver probe 138, as discussed herein.

Receiver probe 138 may be configured to receive and/or detect energy.Specifically, receiver probe 138 may be configured to receive the energytransmitted from transmitter probe 132 of inspection system 130. In anon-limiting example, transmitter probe 132 and receiver probe 138 mayuse a “pitch-catch” technique or process for transmitting and receivingenergy. As shown in FIG. 2, the energy transmitted by transmitter probe132 may pass through rotor 110 to a focal point 142 of rotor 110. Theenergy may deflect and/or bounce from focal point 142 toward receiverprobe 138. In another non-limiting example, transmitter probe 132 mayfocus energy toward focal point 142 and receiver probe 138 may onlydetect energy transmitted to focal point 142. The focal point 142 maychange and/or move as transmitter probe 132 and receiver probe 138 movealong and/or around rotor 110, as discussed herein.

The energy transmitted by transmitter probe 132 may be received byreceiver probe 138 to inspect rotor 110 and/or the plurality of features128 formed on rotor 110 and determine if rotor 110 includes defects,and/or requires maintenance before being implemented back into steamturbine steam 100. Additionally, the energy transmitted by transmitterprobe 132 may be received by receiver probe 138, and energycharacteristics (e.g., amplitude, time of flight and so on) relating tothe received energy may be utilized, processed and/or analyzed tomaintain a desired spacing and/or alignment between transmitter probe132 and receiver probe 138 of inspection system 130 during theinspection process. As discussed in detail below, maintaining a desiredspacing and/or alignment between transmitter probe 132 and receiverprobe 138 may be critical to ensuring that inspection system 130 mayadequately inspect rotor 110 and/or the plurality of features 128. In anon-limiting example, transmitter probe 132 may be an ultrasonic, phasedarray sensor or receiver that may receive and/or detect ultrasonicenergy. Although one receiver probe 138 is depicted in FIG. 2, it isunderstood that a plurality of receiver probes may be positioned onrotor 110 and utilized in the inspection process discussed herein.Additionally, the number of receiver probes 138 of inspection system 130may directly correlate with, or may be substantially dependent from, thenumber of transmitter probes 132 of inspection system 130.

Although discussed herein as transmitter probe 132 solely transmittingenergy, and receiver probe 138 solely receiving energy, it is understoodthat the probes of inspection system 130 may perform different tasksand/or functions. In a non-limiting example, each probe (e.g.,transmitter probe 132, receiver probe 138) of inspection system 130 maybe configured to both transmit and receive energy. That is, a firstprobe (e.g., transmitter probe 132) positioned adjacent a first side offeature 128 formed on rotor 110 may be configured to transmit energytoward a second probe (e.g., receiver probe 138) and also receive energytransmitted by the second probe. Similarly, the second probe positionedadjacent a second side of feature 128, opposite the first side, may alsobe configured to transmit energy toward the first probe and receiveenergy transmitted by the first probe. The functions and/or operationsof transmitter probe 132 and receiver probe 138 discussed herein may belimited to performing a single operation (e.g., transmitting energy,receiving energy) merely for simplicity in description of inspectionsystem 130.

Similar to transmitter probe 132, receiver probe 138 may be configuredto move around rotor 110. Specifically, receiver probe 138 may beconfigured to move circumferentially around exposed surface 126 of rotor110 during the inspection process. As shown in FIG. 2, inspection system130 may include a second propulsion assembly 144 that may automate themovement of transmitter probe 132 around rotor 110 and/or along exposedsurface 126. Second propulsion assembly 144 may be coupled or fixed toreceiver probe 138, and may contact exposed surface 126 of rotor 110. Asa result of contacting exposed surface 126, second propulsion assembly144 may releasable couple and/or position receiver probe 138 on exposedsurface 126 of rotor 110. Second propulsion assembly 144 may include anysuitable elements, device and/or components (e.g., magnetic wheels,drivetrain system and the like) that may be configured to move receiverprobe 138 along exposed surface 126 of rotor 110, as similarly discussedherein with respect to first propulsion assembly 136. As discussedherein, and similar to first propulsion assembly 136, second propulsionassembly 144 may be in communication with a probe alignment system whichmay engage second propulsion assembly 144 to move receiver probe 138around rotor 110. Additionally, and as discussed herein, the probealignment system may adjust displacement characteristics of receiverprobe 138 using second propulsion assembly 144 to maintain an alignmentbetween transmitter probe 132 and receiver probe 138 during theinspection process.

Inspection system 130 may also include probe alignment system 146. Asshown in FIG. 2, probe alignment system 146 may be coupled to, operablyconnected to and/or in electrical communication with transmitter probe132 and receiver probe 138 of inspection system 130. As discussedherein, probe alignment system 146 may be in electrical communicationwith transmitter probe 132 and receiver probe 138 such that probes 132,138 may provide information, data and/or energy characteristics relatingto the energy transmitted by transmitter probe 132 and/or received byreceiver probe 138. As discussed herein, probe alignment system 146 mayanalyze the energy characteristics to determine if displacementcharacteristics for the transmitter probe 132 and/or receiver probe 138require adjustment. Additionally as discussed herein, probe alignmentsystem 146 may also be operably connected to and/or in electricalcommunication with first propulsion assembly 136 and second propulsionassembly 144 to adjust displace characteristics of transmitter probe 132and/or receive probe 138 using propulsion assemblies 136, 144. Innon-limiting examples, the energy characteristics may include anamplitude of the energy received by receiver probe 138, a time of flightor travel for the energy to be transmitted from transmitter probe 132and received by receiver probe 138, and any other energy-relatedinformation that may be detected by receiver probe 138, analyzed byprobe alignment system 146 and utilized to maintain a desired alignmentor spacing between transmitter probe 132 and receiver probe 138 duringan inspection process, as discussed herein.

As shown in FIG. 2, probe alignment system 146 may include an energymodule 148, a probe displacement module 150 and a storage device 152.Energy module 148, probe displacement module 150 and storage device 152may all be operably connected and/or in electrical communication withone another. As a result, energy module 148, probe displacement module150 and storage device 152 may share, obtain and/or transfer data duringthe inspection process. Energy module 148 may be configured to obtainthe energy characteristics relating to the energy received by receiverprobe 138 and analyze the energy characteristics to determine ifdisplacement characteristics of transmitter probe 132 and/or receiverprobe 138 require adjustment.

Probe displacement module 150 may be configured to receive informationfrom energy module 148 when energy module 148 determines thatdisplacement characteristics of transmitter probe 132 and/or receiverprobe 138 require adjustment. Additionally, probe displacement module150 may be configured to perform additional processes to ensuretransmitter probe 132 and receiver probe 138 remain and/or are movedback into a desired alignment and/or spacing when performing theinspection process. In a non-limiting example where the movement oftransmitter probe 132 and receiver probe 138 is automated (e.g.,propulsion assemblies), probe displacement module 150 may also beconfigured to adjust the displacement characteristics of transmitterprobe 132 and/or receiver probe 138 based on the analyzed energycharacteristics and determination of energy module 148. In anothernon-limiting example where the movement of transmitter probe 132 andreceiver probe 138 is manually performed (e.g., operator), probedisplacement module 150 may be configured to provide instructions to theoperator regarding the specific displacement characteristics fortransmitter probe and/or receiver probe 138 that require adjustment.Probe displacement module 150 may provide instructions to the operatorvia an output device (e.g., computer display, printer and so on) (notshown) in communication with probe alignment system 146. Thedisplacement characteristics for transmitter probe 132 and receiverprobe 138 may include, but are not limited to, the speed in which probes132, 138 move along exposed surface 126 and/or around rotor 110, acircumferential position of probes 132, 138 with respect to rotor 110,an axial position of probes 132, 138 with respect to rotor 110, an axialdistance (D) between probes 132, 138 and other characteristics thatmaintain a desired alignment or spacing between transmitter probe 132and receiver probe 138 during an inspection process, as discussedherein.

Storage device 152 may be configured to store information and/or datarelating to the inspection process performed by the inspection system130, and more specifically, information and/or data pertaining to thealignment and/or spacing between transmitter probe 132 and receiverprobe 138 when performing the inspection process. The information may bestored on storage device 152 prior to performing the inspection process.In a non-limiting example, a predetermined desired amplitude and/or apredetermined desired time of flight for the energy transmitted bytransmitter probe 132 may be stored on storage device 152 and sent orobtained by energy module 148 when analyzing the energy characteristics,as discussed herein. Additionally, the information stored on storagedevice 152 may be provided and/or continuously updated while performingthe inspection process. For example, energy module 148 may receiveenergy characteristics for the energy received by receiver probe 138 andmay be configured to determine a desired amplitude and/or desired timeof flight or the energy based on the energy characteristics. Once energymodule 148 determines the desired amplitude and/or desired time offlight, energy module 148 may provide and store that information and/ordata to storage device 152. During the analyze of energycharacteristics, energy module 148 may obtain and/or recall the storedinformation and/or data (e.g., desired amplitude) from storage device152, and compare the stored information and/or data from storage device152 with the energy characteristics (e.g., detected amplitude) for theenergy received by receiver probe 138.

Although shown as a standalone component and/or system, it is understoodthat probe alignment system 146 may be formed integrally with and/or maybe a portion of an overall system or component used when inspectingrotor 110. That is, probe alignment system 146 may be its own system, oralternatively, may be part of a larger system that is in communicationwith transmitter probe 132 and receiver probe 138, and is utilized toperform the inspection process discussed herein.

Aligning and maintaining an alignment for transmitter probe 132 andreceiver probe 138 while performing an inspection process on rotor 110may now be discussed with reference to FIG. 2. During the inspectionprocess transmitter probe 132 and receiver probe 138 may be coupled toand/or positioned on exposed surface 126 of rotor 110. Transmitter probe132 may transmit ultrasonic energy through and/or around rotor 110 andreceiver probe 138 may receive the ultrasonic energy in order to detectdefects of rotor 110 and/or determine the need for maintenance beforeutilizing rotor 110 in steam turbine system 100 (see, FIG. 1). In orderto inspect the entire rotor 110, transmitter probe 132 and receiverprobe 138 may utilize propulsion assemblies 136, 144 to move transmitterprobe 132 and receiver probe 138 circumferentially around rotor 110.

In order to obtain the most accurate inspection information about rotor110 using inspection system 130, transmitter probe 132 and receiverprobe 138 should maintain an optimum positioning on rotor 110, axialspacing and/or axial alignment when performing the inspection process.The optimum positioning, spacing and/or alignment may be based on and/ordetermined using energy characteristics for the ultrasonic energyreceived by receiver probe 138 of inspection system 130. Specifically,energy module 148 of probe alignment system 146 may determine a desiredamplitude and/or desired time of flight for the energy received byreceiver probe 138 that may ensure that transmitter probe 132 andreceiver probe 138 are performing the most accurate inspection of rotor110 during the inspection process. In a non-limiting example, thedesired amplitude may be a maximum amplitude for the energy transmittedby transmitter probe 132 and received by receiver probe 138.Additionally, the desired time of flight for the energy received byreceiver probe 138 may be 0.25 seconds. The amplitude and/or time offlight for the energy received by receiver probe 138 may be dependent,at least in part on, the strength and/or operational characteristics oftransmitter probe 132, the size (e.g., diameter, circumference) of rotor110, the material of rotor 110, the size and/or geometry of theplurality of features 128 of rotor 110, and so on.

Once the desired amplitude and/or desired time of flight for the energyis determined, probe alignment system 146 may continuously, orperiodically, obtain/receive, and subsequently analyze energycharacteristics from receiver probe 138 during the inspection process.The energy characteristics may include the actual or detected amplitudeand/or time of flight for the energy being received by the receiverprobe 138 while inspection system 130 is performing the inspectionprocess on rotor 110. In analyzing the energy characteristics, energymodule 148 of probe alignment system 146 may compare the detectedamplitude and/or time of flight for the energy received by the receiverprobe 138 with the desired amplitude and/or time of flight to determineif the detected amplitude and/or time of flight differ from the desiredamplitude and/or time of flight. If the detected amplitude and/or timeof flight do not differ from the desired amplitude and/or time offlight, probe alignment system 146 may determine that transmitter probe132 and receiver probe 138 are optimally positioned, spaced and/oraligned to provide the most accurate inspection of rotor 110. As such,the displacement characteristics of transmitter probe 132 and/orreceiver probe 138 may not require adjustment. However, if the detectedamplitude and/or time of flight do differ from the desired amplitudeand/or time of flight, energy module of probe alignment system 146 maydetermine that the displacement characteristics of transmitter probe 132and/or receiver probe 138 may require adjustment so transmitter probe132 and receiver probe 138 may subsequently provide the most accurateinspection of rotor 110.

When energy module 148 of probe alignment system 146 determines thatdisplacement characteristics of transmitter probe 132 and/or receiverprobe 138 may require adjustment, energy module 148 may communicate withprobe displacement module 150. Specifically, energy module 148 mayidentify and/or instruct probe displacement module 150 that displacementcharacteristics of transmitter probe 132 and/or receiver probe 138 mayrequire adjustment, and may also provide information relating to theenergy characteristics for the energy received by receiver probe 138.The information relating to the energy characteristics provided to probedisplacement module 150 may include how the detected amplitude and/ortime of flight differs from the desired amplitude and/or time of flight(e.g., greater than, less than). Probe displacement module 150 mayutilize and/or analyze the information relating to the energycharacteristics provided by energy module 148 to determine whichdisplacement characteristic(s) of transmitter probe 132 and/or receiverprobe 138 may be adjusted to put transmitter probe 132 and receiverprobe 138 back in an optimally position, spacing and/or alignment forthe inspection process.

In a non-limiting example, energy module 148 may determine that thedetected amplitude does not differ from the desired amplitude, but thedetected time of flight is less than the desired time of flight. In thisnon-limiting example, probe displacement module 150 may determine thatthe receiver probe 138 is staggered to far behind the transmitter probe132, and needs to be moved forward. As a result, the speed oftransmitter probe 132 may be temporarily decreased and/or the speed ofreceiver prove 138 may be temporarily increased until it is determinedthat the detected time of flight does not differ (e.g., equal) from thedesired time of flight.

In another non-limiting example, energy module 148 may determine thatthe detected amplitude differs from or is less than the desiredamplitude, but the detected time of flight does not differ from thedesired time of flight. In this non-limiting example, probe displacementmodule 150 may determine that transmitter probe 132 and receiver probe138 is axially separated beyond an optimum or desired distance (D), andthe axial position of transmitter probe 132 and/or receiver probe 138needs to be adjusted. In the non-limiting example, receiver probe 138may be moved axially toward transmitter prove 132 and feature 128 untiltransmitter probe 132 and receiver probe 138 are axially spaced orseparated by an optimum or desired distance (D), as shown in FIG. 3.Once transmitter probe 132 and receiver probe 138 are axially spaced orseparated by the desired distance (D), the detected amplitude may notdiffer (e.g., equal) from the desired amplitude.

In another non-limiting example, energy module 148 may determine thatthe detected amplitude differs from or is less than the desiredamplitude, but the detected time of flight does not differ from thedesired time of flight. In this non-limiting example, probe displacementmodule 150 may determine that transmitter probe 132 and receiver probe138 is axially separated beyond an optimum or desired distance (D), andthe axial position of transmitter probe 132 and/or receiver probe 138needs to be adjusted. In the non-limiting example, receiver probe 138may be moved axially toward transmitter prove 132 and feature 128 untiltransmitter probe 132 and receiver probe 138 are axially spaced orseparated by an optimum or desired distance (D), as shown in FIG. 3.Once transmitter probe 132 and receiver probe 138 are axially spaced orseparated by the desired distance (D), the detected amplitude may notdiffer (e.g., equal) from the desired amplitude.

In a further non-limiting example, energy module 148 may determine thatthe detected amplitude and time of flight differ from the desiredamplitude and time of flight. In this non-limiting example, probedisplacement module 150 may adjust one or more displacementcharacteristics (e.g., speed, position, axial separation and so on) fortransmitter probe 132 and/or receiver probe 138 until the detectedamplitude and time of flight no longer differ from the desired amplitudeand time of flight.

As discussed herein, probe displacement module 150 may adjust thedisplacement characteristics for transmitter probe 132 and/or receiverprobe 138 by providing instructions and/or electrical signals to therespective propulsion assemblies 136, 144 coupled to and configured tomove transmitter probe 132 and/or receiver probe 138. In anothernon-limiting example where transmitter probe 132 and receiver probe 138are manually moved around rotor 110 during the inspection process, probedisplacement module 150 may provide instructions to the operator ofinspection system 130 highlighting and/or indicating the adjustmentsthat need to be made to transmitter probe 132 and/or receiver probe 138.

As shown in FIG. 2, transmitter probe 132 and receiver probe 138 may bein axial alignment and/or in a similar axial plane when in an optimalposition, spacing and/or alignment to provide the most accurateinspection of rotor 110. This may be a result of rotor 110 having auniform and/or single diameter and/or circumference. That is, theportion of rotor 110 that transmitter probe 132 is position on may havethe same diameter and circumference as the portion of rotor 110 thatreceiver probe 138 is positioned on. As a result, when transmitter probe132 and receiver probe 138 are optimally positioned, spaced and/oraligned, the probes 132, 138 may also be in axial alignment with respectto rotor 110. Although shown as aligned, it is understood that thepositioning and/or spacing of transmitter probe 132 and receiver probe138 shown in FIG. 2 is merely exemplary, and is not limiting. Asdiscussed herein, the optimal positioning, spacing and/or alignment isdependent on a desired amplitude and time of flight for the energyreceived by receiver probe 138. As such, transmitter probe 132 andreceiver probe 138 may be axially staggered on rotor 110 and stilloptimally positioned, spaced and/or alignment, regardless of theconfiguration and/or geometry (e.g., diameter, circumference) of rotor110 undergoing the inspection process discussed herein.

FIG. 3 depicts a side view of a distinct portion of rotor 110 of steamturbine system 100, according to embodiments. FIG. 3 also depictsinspection system 130 used to inspect the distinct portion of rotor 110,as discussed herein. Propulsion assemblies 136, 142 have been omittedfrom FIG. 3 for clarity. However, it is understood that transmitterprobe 132 and/or receiver probe 138 may include propulsion assemblies136, 142, respectively, for moving the probes along exposed surface 126of rotor 110, as discussed herein with respect to FIG. 2. It isunderstood that similarly numbered and/or named components may functionin a substantially similar fashion. Redundant explanation of thesecomponents has been omitted for clarity.

The distinct portion of rotor 110 depicted in FIG. 3 may include twodistinct segments. Specifically, and as shown in FIG. 3, the depictedportion of rotor 110 may include a first segment 154 and a secondsegment 156 coupled to first segment 154. First segment 154 and secondsegment 156 may be coupled using any suitable coupling and/or materialjoining technique including, but not limited to, welding, brazing,mechanical fastening, and the like. As discussed herein, rotor 110 mayinclude a plurality of features 128. In the non-limiting example shownin FIG. 3, the coupling joint formed between first segment 154 andsecond segment 156 may be a feature 128 of rotor 110. As discussedherein, the feature 128 (e.g., joint) of rotor 110 may substantiallyobstruct, obscure and/or block a line of sight between transmitter probe132 and receiver probe 138.

As shown in FIG. 3, first segment 154 and second segment 156 may havevarying diameters. More specifically, first segment 154 may include afirst diameter (Dial) and second segment 156 may include a seconddiameter (Diaz), distinct from the first diameter (Dial) of firstsegment 154. In the non-limiting example shown in FIG. 3, the firstdiameter (Dial) of first segment 154 may be larger than the seconddiameter (Diaz) of second segment 156. As a result, a circumference forfirst segment 154 may also be larger than a circumference for secondsegment 156.

As a result of the varying diameters and/or circumferences for firstsegment 154 and second segment 156 forming rotor 110, transmitter probe132 and receiver probe 138 may not be aligned in similar positionsand/or in a similar manner as when rotor 110 has a uniform or singlediameter (see, FIG. 2). In the non-limiting example shown in FIG. 3,transmitter probe 132 and receiver probe 138 of inspection system 130may be positioned such that the amplitude and time of flight for theenergy received by receiver probe 138 is equal to the desired amplitudeand/or time of flight for optimum inspection of rotor 110, as discussedherein. Compared to the example in FIG. 2, transmitter probe 132 andreceiver probe 138 may be axially out of alignment. That is, transmitterprobe 132 positioned on first segment 154 may be axially staggered fromand/or in a distinct axial plane than receiver probe 138 positioned onsecond segment 156. The staggering between transmitter probe 132 andreceiver probe 138 to maintain the desired amplitude and/or time offlight for the energy received by receiver probe 138 may be a result ofthe distinct diameters between first segment 154 and second segment 156.Although transmitter probe 132 is shown as being staggered and/orpositioned in front of receiver probe 138 it is understood that this ismerely a non-limiting example, and in some instances, receiver probe 138may be positioned in front of transmitter probe 132 during an inspectionprocess.

FIG. 4 depicts a side view of a portion of rotor 110 of steam turbinesystem 100 similar to the portion shown in FIG. 2. FIG. 4 also depictsinspection system 130 used to inspect the distinct portion of rotor 110,as discussed herein. It is understood that similarly numbered and/ornamed components may function in a substantially similar fashion.Redundant explanation of these components has been omitted for clarity.

Inspection system 130 shown in FIG. 4 may include additional componentsused to align and/or maintain alignment between transmitter probe 132and receiver probe 138 during the inspection process of rotor 110discussed herein. Specifically, inspection system 130 may also includean encoder 158 and inclinometers 160, 162. As shown in FIG. 4, encoder158 may be positioned on an end 164 of rotor 110 of steam turbine system100. Specifically, encoder 158 may be coupled to end 164 of rotor 110and may be positioned in axial alignment with a center of rotor 110.Encoder 158 may be operably connected to and/or in electricalcommunication with probe alignment system 146 and inclinometers 160, 162of inspection system 130. In a non-limiting example, encoder 158 may behardwired to probe alignment system 146 and may in wirelesscommunication with inclinometers 160, 162 in order to share data frominclinometers 160, 162 with probe alignment system 146. As discussedherein, encoder 158 may define a “0 degree” mark or reference forinclinometers 160, 162 coupled to transmitter probe 132 and receiverprobe 138, respectively, so probe alignment system 146 may detect thecircumferential movement and/or position of transmitter probe 132 andreceiver probe 138 as they move around rotor 110.

As shown in FIG. 4, first inclinometer 160 may be coupled to, formedand/or positioned on transmitter probe 132, and a second inclinometer162 may be coupled to, formed and/or positioned on receiver probe 138.In another non-limiting example, first inclinometer 160 may be coupledto and/or positioned on first propulsion assembly 136, and secondinclinometer 162 may be coupled to and/or positioned on secondpropulsion assembly 144. Inclinometers 160, 162 may also move with therespective probes 132, 138 during the inspection process. Specifically,first inclinometer 160 coupled to and/or positioned on transmitter probe132 may move with and/or be carried by transmitter probe 132 astransmitter probe 132 moves along exposed surface 126 of rotor 110during the inspection process. Additionally, second inclinometer 162coupled to and/or positioned on receiver probe 138 may move with and/orbe carried by receiver probe 138 as receiver probe 138 moves alongexposed surface 126 of rotor 110 during the inspection process. In anon-limiting example, inclinometers 160, 162 may be operably connectedto and/or in electrical communication with probe alignment system 146for transmitting data or information relating to the position (e.g.,angle) of transmitter probe 132 and receiver probe 138, respectively, toprobe alignment system 146 during the inspection process. Inclinometers160, 162 may be any suitable instruments or components that may beconfigured to detect and/or measure the angle of transmitter probe 132and receiver probe 138 with respect to rotor 110, as discussed herein.

Encoder 158, and inclinometers 160, 162 of inspection system 130 may beutilized to detect and/or determine the circumferential position oftransmitter probe 132 and receiver probe 138 on rotor 110 andsubsequently aid in the alignment of transmitter probe 132 and receiverprobe 138. That is, during the inspection process, encoder 158positioned on end 164 may define a “0 degree” mark or reference for thecircumference of rotor 110 to be utilized by inclinometers 160, 162.Inclinometers 160, 162 may be configured to measure the angle oftransmitter probe 132 and receiver probe 138, as defined by encoder 158(e.g., 0 degree mark), as transmitter probe 132 and receiver probe 138move around rotor 110 during the inspection process. Specifically, firstinclinometer 160 may be configured to measure the angle of transmitterprobe 132 and second inclinometer 162 may be configured to measure theangle of receiver probe 138 during the inspection process. Data orinformation relating to the angle of transmitter probe 132 and receiverprobe 138 may be sent and/or transmitted to encoder 158 and/or probealignment system 146 to be analyzed by probe alignment system 146. Assimilarly discussed above with respect to analyzing the energycharacteristics transmitted by receiver probe 138, the data orinformation relating to the angle of transmitter probe 132 and receiverprobe 138 obtained by encoder 158 and/or inclinometers 160, 162 may beutilized to ensure transmitter probe 132 and receiver probe 138 remainand/or are moved back into a desired (axial) alignment when performingthe inspection process. In a non-limiting example, first inclinometer160 may determine that transmitter probe 132 is positioned at the 180°mark on rotor 110, and second inclinometer 160 may determine thatreceiver probe 138 is positioned at the 145° mark on rotor 110. In thenon-limiting example, it may be determined that transmitter probe 132and receiver probe 138 should be in axial alignment on rotor 110 toensure the most accurate inspection results. As a result, probealignment system 146 may determine that transmitter probe 132 andreceiver probe 138 are not properly aligned based on the data frominclinometers 160, 162 and may subsequently adjust the displacementcharacteristics (e.g., speed, position) of transmitter probe 132 and/orreceiver probe 138 to put the probes 132, 138 in axial alignment (e.g.,180° mark).

In a non-limiting example, encoder 158 and inclinometers 160, 162 may beconcurrently or simultaneously with transmitter probe 132 and receiverprobe 138 for detecting and/or maintaining alignment of transmitterprobe 132 and receiver probe 138 during the inspection process. Inanother non-limiting example, encoder 158 and inclinometers 160, 162 maybe used exclusively for detecting and/or the circumferential position oftransmitter probe 132 and receiver probe 138 to ensure alignment betweentransmitter probe 132 and receiver probe 138 during the inspectionprocess. In this non-limiting example, transmitter probe 132 andreceiver probe 138 may still perform operations discussed herein toensure a desired spacing or distance (D) is maintained betweentransmitter probe 132 and receiver probe 138 during the inspectionprocess.

FIG. 5 depicts an example process for aligning inspection probes of aninspection system. Specifically, FIG. 5 is a flowchart depicting oneexample process 200 for aligning and maintaining alignment between atransmitter probe and a receiver probe of an inspection system whileperforming an inspection process on a rotor.

In operation 202, initial preparation processes may be performed.Specifically, preparation processes may be performed on the rotor thatmay undergo the inspection process using the inspection system. Thepreparation processes may include, but are not limited to, removing therotor from a housing and/or enclosure of the turbine system, androughening the surface of the rotor. Roughening the surface of the rotormay include, for example, sand-blasting the surface of the rotor toimprove inspection results. Preparation processes can also includereleasably coupling at least one transmitter probe and at least onereceiver probe to the exposed surface of the rotor. The transmitterprobe may be releasably coupled to the rotor on a first side of afeature of the rotor, and the receiver probe may be releasably coupledto the rotor on a second side of the feature. The second side of thefeature may be opposite the first side. As such, the feature maysubstantially block the line of sight between the transmitter probe andthe receiver probe.

In operation 204, the transmitter probe releasably coupled to the rotormay be moved on the rotor. Specifically, the transmitter probe may bemoved along the exposed surface of the rotor and/or may movecircumferentially around the exposed surface of the rotor. In anon-limiting example, the movement of the transmitter probe mayautomated and the transmitter probe may include a propulsion assemblyconfigured to move the transmitter probe around the rotor. In anothernon-limiting example, the movement of the transmitter probe may be donemanually by an operator performing the inspection process on the rotor.

In operation 206, the receiver probe releasably coupled to the rotor mayalso be moved around the rotor. Specifically, and similar to themovement of the transmitter probe in operation 204, the receiver probemay be moved along the exposed surface of the rotor and/or may movecircumferentially around the exposed surface of the rotor. Innon-limiting examples, the movement of the receiver probe may automated(e.g., a propulsion assembly), or alternatively, may be manual (e.g.,operator).

Although shown in FIG. 5 as being linear and/or performed in succession,it is understood that operation 204 and operation 206 may be performedsimultaneously. That is, the movement of the transmitter probe inoperation 204 and the movement of the receiver probe in operation 206may happen simultaneously, such that both the transmitter probe andreceiver probe are both moving along the exposed surface of the rotor.Additionally, it is understood that operation 204 and operation 206 maybe performed independent of one another. That is, the movement of thetransmitter probe may be independent from the movement of the receiverprobe.

In operation 208, energy characteristics for the energy received by thereceiver probe may be analyzed. Specifically, energy characteristicsincluding, but not limited to, a detected amplitude and/or a detectedtime of flight or travel for the energy received by the receiver probemay be analyzed. Analyzing the energy characteristics may also includedetermining a desired amplitude for the energy received by the receiverprobe, and/or determining a desired time of flight for the energyreceived by the receiver probe. Determining the desired amplitude and/ortime of flight may be accomplished when performing the analysis processin operation 208. Alternatively, determining the desired amplitudeand/or time of flight may be accomplished prior to the analysis processin operation 208. For example, the desired amplitude and/or time offlight may be determined when performing the initial preparationprocesses in operation 202. Analyzing the energy characteristics mayalso include comparing the detected amplitude of the energy received bythe receiver probe with the determined, desired amplitude, anddetermining if the detected amplitude differs from the desiredamplitude. Also, analyzing the energy characteristics may includecomparing the detected time of flight of the energy received by thereceiver probe with the determined, desired time of flight, anddetermining if the detected time of flight differs from the desired timeof flight. If it is determined that the detected amplitude and/or timeof flight differs from the determined, desired amplitude and/or time offlight, then the analyzing of operation 208 may also include determiningthat the transmitter probe and the receiver probe are out of alignmentand displacement characteristics of the transmitter probe and/or thereceiver probe may require adjustment.

In operation 210, displacement characteristics for the transmitter probeand/or the receiver probe may be adjusted based on the analyzed energycharacteristics. Specifically, when it is determined that detectedamplitude and/or time of flight differs from the determined, desiredamplitude and/or time of flight, displacement characteristics for thetransmitter probe and/or the receiver probe may be adjusted to realignand/or reposition the transmitter probe and the receiver probe on therotor. The realignment and/or repositioning achieved by adjustingdisplacement characteristics of the transmitter probe and/or thereceiver probe may allow the transmitter probe and the receiver probe toprovide optimum inspection results when performing the inspectionprocess on the rotor. Adjusting the displacement characteristics of thetransmitter probe and/or the receiver probe may include altering a speedof the transmitter probe and/or the receiver probe, altering acircumferential position of the transmitter probe and/or the receiverprobe with respect to the rotor, altering an axial position of thetransmitter probe and/or the receiver probe with respect to the rotor,and/or altering an axial distance the transmitter probe and/or thereceiver probe. Additionally, adjusting the displacement characteristicsof the transmitter probe and/or the receiver probe may include axiallyaligning the transmitter probe and the receiver probe in response to therotor undergoing the inspection process having a uniform and/or singlediameter and circumference. Furthermore, adjusting the displacementcharacteristics of the transmitter probe and/or the receiver probe mayinclude axially staggering the transmitter probe and the receiver probein response to the transmitter probe being positioned on a first segmentof the rotor having a first diameter and first circumference, and thereceiver probe being positioned on a second segment of the rotor havinga second diameter and second circumference. The second diameter andsecond circumference of the second segment may be smaller than the firstdiameter and first circumference of the first segment.

Although discussed herein as performing an inspection process on a rotorof a turbine, it is understood that the inspection process performedusing the inspection system may be performed on any substantially round,and/or circular shaft or component. That is, the inspection processincluding methods or operations for maintaining an aligning between theinspection probes of the inspection system discussed herein may not belimited to just being performed on a turbine rotor. Rather, theinspection system and alignment operations may be performed on anycomponent that may require inspection and/or may include features thatsubstantially obstruct the line of sight between two inspection probesof the system.

The foregoing description, for purposes of explanation, used specificnomenclature to provide a thorough understanding of the describedembodiments. However, it will be apparent to one skilled in the art thatthe specific details are not required in order to practice the describedembodiments. Thus, the foregoing descriptions of the specificembodiments described herein are presented for purposes of illustrationand description. They are not target to be exhaustive or to limit theembodiments to the precise forms disclosed. It will be apparent to oneof ordinary skill in the art that many modifications and variations arepossible in view of the above teachings.

We claim:
 1. An inspection system comprising: a first ultrasonic probe positioned on and configured to move along a surface of a component, the first ultrasonic probe configured to transmit ultrasonic energy; a second ultrasonic probe positioned on and configured to move along the surface of the component opposite the first probe, the second ultrasonic probe configured to receive the ultrasonic energy transmitted by the first ultrasonic probe; and a probe alignment system in communication with the first ultrasonic probe and the second ultrasonic probe, the probe alignment system configured to: analyze an energy characteristic for the ultrasonic energy received by the second ultrasonic probe to determine if a displacement characteristic for at least one of the first ultrasonic probe and the second ultrasonic probe requires adjustment.
 2. The inspection system of claim 1, wherein the energy characteristic for the ultrasonic energy comprises at least one of: an amplitude of the ultrasonic energy received by the second ultrasonic probe; and a time of flight for the ultrasonic energy to be transmitted from the first ultrasonic probe and received by the second ultrasonic probe.
 3. The inspection system of claim 2, wherein the probe alignment system is further configured to: determine a desired amplitude for the ultrasonic energy received by the second ultrasonic probe; and determine a desired time of flight for the ultrasonic energy received by the second ultrasonic probe.
 4. The inspection system of claim 3, wherein the probe alignment system is further configured to: compare the amplitude of the ultrasonic energy with the desired amplitude; and compare the time of flight of the ultrasonic energy with the desired time of flight.
 5. The inspection system of claim 1, wherein the displacement characteristic comprises at least one of: a speed of at least one of the first ultrasonic probe and the second ultrasonic probe; a position of at least one of the first ultrasonic probe and the second ultrasonic probe with respect to the component; and a distance between the first ultrasonic probe and the second ultrasonic probe.
 6. The inspection system of claim 1 further comprising: a first propulsion assembly coupled to the first ultrasonic probe; and a second propulsion assembly coupled to the second ultrasonic probe.
 7. The inspection system of claim 6, wherein the probe alignment system is in communication with the first propulsion component and the second propulsion component, and is configured to: adjust the displacement characteristic for at least one of the first ultrasonic probe and the second ultrasonic probe requires adjustment in response to analyzing the energy characteristic for the ultrasonic energy received by the second ultrasonic probe.
 8. The inspection system of claim 1, wherein the first ultrasonic probe and the second ultrasonic probe are positioned on opposite sides of a feature formed on the component, the feature substantially obstructing a line of sight between the first ultrasonic probe and the second ultrasonic probe.
 9. The inspection system of claim 1, further comprising: an encoder positioned on an end of the component, the encoder axially aligned with a center of the component; a first inclinometer positioned on the first ultrasonic probe, the first inclinometer in communication with the encoder and the probe alignment system; and a second inclinometer positioned on the second ultrasonic probe, the second inclinometer in communication with the encoder and the probe alignment system.
 10. A rotor comprising: a plurality of features formed on and extending from an exposed surface; and an inspection system comprising: at least one transmitter probe positioned on the exposed surface and adjacent the plurality of features, the at least one transmitter probe configured to transmit energy; at least one receiver probe positioned on the exposed surface and separated from the at least one transmitter probe by the plurality of features, the at least one receiver probe configured to receive the energy transmitted by the at least one transmitter probe; and a probe alignment system in communication with the at least one transmitter probe and the at least one receiver probe, the probe alignment system configured to: analyze an energy characteristic for the ultrasonic energy received by the at least one receiver probe to determine if a displacement characteristic for at least one of the at least one transmitter probe and the at least one receiver probe requires adjustment.
 11. The rotor of claim 10, wherein the at least one transmitter probe is an ultrasonic phased array transducer.
 12. The rotor of claim 10, wherein at least one feature of the plurality of features comprises a joint formed between a first segment of the rotor and a second segment of the rotor.
 13. The rotor of claim 12, wherein the first segment of the rotor includes a first diameter that is larger than a second diameter of the second segment of the rotor.
 14. The rotor of claim 13, wherein the at least one transmitter probe positioned on the first segment of the rotor is axially staggered from the at least one receiver probe positioned on the second segment of the rotor.
 15. The rotor of claim 10, wherein the displacement characteristic comprises at least one of: a speed of at least one of the at least one transmitter probe and the at least one receiver probe; a circumferential position of the at least one transmitter probe and the at least one receiver probe with respect to the rotor; and an axial position of the at least one transmitter probe and the at least one receiver probe with respect to the single feature of the plurality of features separating the at least one transmitter probe and the at least one receiver probe.
 16. A method for aligning inspection probes, the method comprising: moving a first ultrasonic probe along a surface of a component, the first ultrasonic probe configured to transmit energy; moving a second ultrasonic probe along the surface of the component, the second ultrasonic probe configured to receive the energy transmitted by the first ultrasonic probe; analyzing an energy characteristic for the energy received by the second ultrasonic probe; and adjusting a displacement characteristic for at least one of the first ultrasonic probe and the second ultrasonic probe based on the analyzed energy characteristic.
 17. The method of claim 16 further comprising: roughening the surface of the component; releasably coupling the first ultrasonic probe to the component on a first side of a feature formed on the component; and releasably coupling the second ultrasonic probe to the component on a second side of the feature formed on the component, the second side of the feature opposite the first side.
 18. The method of claim 16 further comprising: determining a desired amplitude for the ultrasonic energy received by the second ultrasonic probe; and determining a desired time of flight for the ultrasonic energy received by the second ultrasonic probe.
 19. The method of claim 18, wherein analyzing the energy characteristic further comprises: detecting an amplitude of the ultrasonic energy received by the second ultrasonic probe; determining if the detected amplitude of the ultrasonic energy differs from the desired amplitude; detecting a time of flight of the ultrasonic energy transmitted from the first ultrasonic probe and received by the second ultrasonic probe; and determining if the detected time of flight of the ultrasonic energy differs from the desired time of flight.
 20. The method of claim 16, wherein adjusting the displacement characteristic for at least one of the first ultrasonic probe and the second ultrasonic probe comprises: altering a speed of at least one of the first ultrasonic probe and the second ultrasonic probe; altering a position of at least one of the first ultrasonic probe and the second ultrasonic probe with respect to the component; and altering a distance between the first ultrasonic probe and the second ultrasonic probe. 